Ergonomic mold manipulator

ABSTRACT

A mold press includes an upper mold carrier mounted to slide up and down along an upright mold press frame and to rotate about a horizontal rotation axis. The mold press frame is supported on a mold press base to tip forward and aft about a horizontal upper mold pivot axis disposed parallel to and below the rotation axis. A lower mold carrier is supported on the mold press base below the upper mold carrier and above the upper mold pivot axis. The lower mold carrier includes a lower mold mounting plate that is pivotally supported on the mold press base for tipping motion along a hinged edge about a lower mold pivot axis that lies parallel to and below the rotation axis and above the upper mold pivot axis. An electronic motion controller may be programmed to coordinate the reciprocating, tipping and rotating motions to accommodate a variety of mold/retainer configurations. The motion controller may be also be programmed to move the upper mold carrier and an attached upper mold portion into ergonomically optimum positions that meet different operations&#39; needs.

This is a continuation, of application Ser. No. 08/864,767, filed on May28, 1997, now U.S. Pat. No. 5,919,494, which is incorporated herein byreference.

TECHNICAL FIELD

This invention relates generally to mold presses and, more particularly,to mold presses for carrying various forms of mold sections at differentvertical height relationships with respect to a mold press frame whilefurther providing drives and supports for positioning upper and lowermold carriers for ease of operator access for replacing mold sectionsand for removing molded products from mold sections mounted on the moldcarriers.

BACKGROUND OF THE INVENTION

Various mold presses are known in which upper and lower mold carriersare vertically reciprocated during a mold process by hydraulic cylindersto apply, maintain and release clamping pressure on upper and lower moldsections that are attached to the upper and lower mold carriers,respectively. In such cases it is also known to include hydraulic drivesfor pivoting the mold carriers in so called booking presses to provideoperators with access to the mold sections attached to the moldcarriers. Operators require such access to remove finished moldedproducts from the mold press, to insert parts, such as retainers andshells in the mold sections prior to injecting or pouring-in foam, andto periodically clean-out mold cavities of the mold sections.

A booking press of this type is disclosed in U.S. Pat. No. 5,282,732issued Feb. 1, 1994 to Eggert. The Eggert patent discloses a mold pressapparatus with an upper mold carrier supported on a mold press frameabove a lower mold carrier supported on a mold press base. The uppermold carrier is supported for pivotal movement about a upper mold pivotaxis that is displaced from the upper mold carrier. The upper moldcarrier is also supported for reciprocal movement toward and away fromthe upper mold pivot axis. However, The Eggert mold press does not bothrotate and pivotally tip the upper mold carrier.

What is needed is a mold press with an upper mold carrier that can berotated and pivotally tipped into positions ergonomically suited tovarious operators and positions that accommodate a variety ofmold/retainer configurations.

SUMMARY OF THE INVENTION

In accordance with this invention a mold press is provided that includesan upper mold tipper and an upper mold rotator that respectively tip androtate the upper mold carrier into a wide range of positions toaccommodate various operators and various mold/retainer configurations.The mold press includes an upper mold carrier supported on a mold pressframe above a lower mold carrier supported on a mold press base. Theupper mold carrier is supported for pivotal movement about a upper moldpivot axis displaced from the upper mold carrier and reciprocal movementtoward and away from the upper mold pivot axis. The upper mold tipperpivotally supports the mold press frame and the upper mold carrier forpivotal tipping motion about the upper mold pivot axis. The upper moldpivot axis is disposed below the upper mold carrier. The upper moldrotator is connected between the mold press frame and the upper moldcarrier and rotatably supports the upper mold carrier about a rotationaxis generally parallel to the upper mold pivot axis.

According to one aspect of the invention each of two slide plateassemblies is mounted for reciprocal movement along one of two parallellift tubes. The upper mold carrier is rotatably supported between thetwo slide plate assemblies.

According to another aspect of the invention one of two stabilizerplates is rotatably supported on each of the slide plate assemblies. Inaddition, one of two idler guides is rotatably supported on each of thetwo slide plate assemblies. Each stabilizer plate has an outercircumferential rim in guided turning engagement with one of the idlerguides.

According to another aspect of the invention a rotator motor isoperatively connected between one of the slide plate assemblies and theupper mold carrier. In addition, a rotator plate is rotatably andcoaxially mounted with and fixed in relation to one of the stabilizerplates for rotation about the rotator axis. The rotator motor is ahydraulic motor supported on the first slide plate assembly and is indriving engagement with the outer circumferential rim of the rotatorplate.

According to another aspect of the invention a chain is fixed along theouter circumferential rim of the rotator plate. The rotator motor isconnected to a drive shaft that is fixed to a chain sprocket and thechain sprocket is in driving engagement with the outer circumferentialchained rim of the rotator plate.

According to another aspect of the invention each of two upper mold liftcylinders is housed within one of the two lift tubes. A lower end ofeach upper mold lift cylinder is fixed within the lift tube it occupiesand an upper end is supported for reciprocal movement within that lifttube. The upper mold lift cylinder upper ends each support one of thetwo slide plate assemblies.

According to another aspect of the invention at least one elongated railis fixed to each lift tube. The slide plate assemblies are movablymounted for reciprocal motion along these elongated rails.

According to another aspect of the invention the upper mold tipper ismovably supported on the mold press base for lateral positionaladjustment relative to the base. This lateral position adjustment allowsan operator to properly position the upper mold in relation to differentlongitudinal and angular lower mold positions on the lower mold carrier.The lateral position adjustment ability also allows an operator toadjust upper mold motion in relation to various lower moldconfigurations.

According to another aspect of the invention the base includes twotipper supports. The tipper supports are disposed at opposite ends ofthe base. Two frame supports are movably supported on the two tippersupports for horizontal position adjustment relative to the base. Theframe supports pivotally connect to the tipper supports. The base mayinclude floor attachments for securing the mold press to a flat surfacesuch as a floor.

According to another aspect of the invention the upper mold tipperincludes at least one tipper drive motor operatively connected betweenthe mold press frame and one of the frame supports. The drive motor is ahydraulic motor that is supported on the first lift tube and is indriving engagement with an upper semi-circular rim of a tipper plate.

According to another aspect of the invention a chain is fixed along theupper semi-circular rim of the tipper plate and the tipper motor driveshaft is fixed to a chain sprocket. The chain sprocket is in drivingengagement with the upper chained rim of the tipper plate.

According to another aspect of the invention the lower mold carrier ispivotally mounted to the base about a lower mold pivot axis that isgenerally parallel to the upper mold pivot axis. At least one lower moldcarrier lift cylinder is connected at one end to the base and at asecond end to the lower mold carrier.

According to one final aspect of the invention the mold press includes amulti-axis motion controller connected to the upper mold tipper, thelower mold tipper, the upper mold rotator and the lift cylinders.

DESCRIPTION OF THE DRAWINGS

To better understand and appreciate the invention, refer to thefollowing detailed description in connection with the accompanyingdrawings:

FIG. 1 is a partially cut-away front view of a mold press constructedaccording to the present invention;

FIG. 2 is a left side view of the mold press of FIG. 1;

FIG. 3 is a cross-sectional view of the right end of the mold press ofFIG. 1 taken along line 3--3;

FIG. 4 is a magnified view of region 4 of the mold press of FIG. 1;

FIG. 5 is a partial top end view of the left end of the mold press ofFIG. 1;

FIG. 6 is a plan view of an upper mold carrier portion of the mold pressof FIG. 1;

FIG. 7 is a cross-sectional end view of the upper mold carrier of FIG. 6taken along line 7--7 of FIG. 6;

FIG. 8 is a partially cut-away plan view of a base frame portion of themold press of FIG. 1; and

FIG. 9 is a cross-sectional side view of the base frame of FIG. 8 takenalong line 9--9 of FIG. 8.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

A mold press assembly constructed according to the present invention isgenerally shown at 10 in FIGS. 1 and 2. The mold press assembly 10includes an upper mold carrier, generally indicated at 12 in FIGS. 1, 2,6 and 7. A mold press frame 14, generally indicated at 14 in FIGS. 1, 2and 5, supports the upper mold carrier 12 in a position above a lowermold carrier, shown at 16 in FIGS. 1, 8 and 9. A mold press base,generally indicated at 18 in FIGS. 1, 2, 8 and 9, supports the lowermold carrier 16 and an upper mold tipper generally indicated at 19 inFIGS. 1 and 2. The upper mold tipper 19 supports the upper mold carrier12 and mold press frame 14 for pivotal "tipping" movement about ahorizontal upper mold pivot axis, shown at 20 in FIGS. 1 and 2. Theupper mold pivot axis 20 is displaced below the upper mold carrier 12.The upper mold carrier 12 is also supported for reciprocal movementtoward and away from the upper mold pivot axis 20 along the mold pressframe 14. An upper mold rotator 21 is connected between the mold pressframe 14 and the upper mold carrier 12. The upper mold rotator 21supports the upper mold carrier 12 on the mold press frame 14 whileallowing the upper mold carrier 12 and an attached upper mold portion torotate about a rotation axis 23. The rotation axis 23 is disposedparallel to the upper mold pivot axis 20 as shown in FIGS. 1 and 2.

An electronic motion controller (not shown) coordinates thereciprocating, tipping and rotating motions to ergonomically positionthe upper mold carrier 12 to meet different operators' needs and toenable the mold press assembly 10 to accommodate a variety ofmold/retainer configurations.

As is best shown in FIG. 1, the mold press frame 14 includes first 22and second 24 parallel lift tubes made from square steel tubing. Whilesquare tubing is used in the illustrated embodiment, other shapes suchas circular, hexagonal, triangular or topographical variants thereofwould also work.

First 26 and second 28 upper mold lift cylinders are coaxially housedwithin the first 22 and second 24 lift tubes, respectively. Each of theupper mold lift cylinders 26, 28 is a Parker Series 2H hydrauliccylinder with a 31/4" bore and a 40 inch stroke.

As is representatively shown in FIG. 1, each of the upper mold liftcylinders 26, 28 has a lower end fixed within its respective lift tube22, 24, and an upper end supported for reciprocal movement within thetube 22, 24. The upper end of each upper mold lift cylinder 26, 28 isconnected to respective Parker #50945 female rod devises 32 that supportrespective first 30 and second 34 slide plate assemblies. A pair of rods36 connect the two female rod devises 32 to their respective slide plateassemblies 30, 34. The rods 36 pass from the female rod devises 32,through longitudinally-oriented slots 37 in the walls of the lift tubes22, 24, and into attachment hubs 38, 40 located at an upper end of eachslide plate assembly 30, 34. As is best shown in FIG. 3, the slots 37extend longitudinally along the approximate upper half of inner-facingside walls 42, 44 of the lift tubes 22, 24. As is representatively shownin FIG. 3, the lift tube slots 37 provide a path in which the rods 36may move reciprocally with the motion of the upper mold lift cylinders26, 28 and slide plate assemblies 30, 34.

As shown in FIGS. 1-3 and 5, a pair of elongated rails 46, 48 isfastened along a portion of the length of each lift tube 22, 24. Onerail of each pair of rails 46, 48 is fastened to a front wall 50, 52 ofeach tube 22, 24 and the other rail of each pair of rails 46, 48 isfastened to a rear wall of each tube 22, 24 opposite the respectivefront wall 50, 52. The rails 46, 48 are made of carbon reinforced steelbut may be made of any other suitable material.

As is representatively shown in FIG. 3, each of the slide plateassemblies 30, 34 includes a vertically-oriented rectangular lift plate54, 56 made from carbon steel plate. As best shown in FIG. 1, each slideplate assembly 30, 34 also includes an upper 58 and a lower 60 pair oflinear motion guide brackets. The upper 58 and lower 60 pairs ofbrackets are attached to upper and lower corners of each lift plate 54,56, respectively. Each pair of linear motion guide brackets 58, 60slideably engages one of the pairs of elongated rails 46, 48 as shown inFIGS. 1, 2 and 5.

As is best shown in FIGS. 7 and 9, the lower mold carrier 16 includes arectangular steel lower mold mounting plate 62 that lies flush on anupper surface of a base frame portion 64 of the mold press base 18. Thelower mold mounting plate 62 is attached to the base frame 64 by threetool hinges 66 and includes provisions for attaching the lower portionof a mold. Mounting feet comprising pieces of angle iron (not shown)attach lower mold portions to the lower mold mounting plate 62. In otherembodiments any suitable means of attaching the lower portion of a moldto a flat mounting plate may be employed. The hinges 66 allow the lowermold carrier steel mounting plate 62 to pivot about a lower mold pivotaxis shown at 68 in FIGS. 1, 8 and 9. The lower mold pivot axis 68 isparallel to both the upper mold pivot axis 20 and the rotation axis 23.

The base frame portion 64 of the mold press base 18 comprises arectangular framework of rectangular steel tubing. As shown in FIGS. 1and 2, floor attachments 70 are bolted to a lower surface of the baseframe 64 to fasten the mold press base 18 to a generally horizontal flatsurface such as a floor.

The mold press base 18 includes first and second tipper supports,generally indicated at 72 and 74 in FIGS. 1, 2 and 8. The tippersupports 72, 74 are disposed at respective first 76 and second 78opposite ends of the base frame 64. As shown in FIGS. 1, 2 and 8, thetipper supports 72, 74 include respective first 80 and second 82elongated rectangular carbon steel tipper-support plates. Eachtipper-support plate 80, 82 is disposed horizontally and is bolted tothe base frame 64 along the respective first 76 and second 78 ends ofthe base frame 64. An upper edge of each tipper-support 72, 74 isnotched and chamfered to provide a sliding rail surface 83, as is bestshown in FIG. 4, for slidably supporting the upper mold tipper 19, moldpress frame 14, upper mold rotator 21 and upper mold carrier 12 forhorizontal fore-aft movement.

The reason the upper mold tipper 19, mold press frame 14, upper moldrotator 21 and upper mold carrier 12 are slidably supported on the baseframe 64 is to allow an operator to adjust the lateral position of theupper mold tipper 19 relative to the mold press base 18 and in afore-aft direction perpendicular to the upper mold pivot axis 20.

As shown in FIG. 1, the upper mold tipper 19 comprises first 84 andsecond 86 frame supports that are movably supported on the respectivefirst 72 and second 74 tipper supports in such a way as to allow thehorizontal position of the frame supports 84, 86 to be adjusted relativeto the mold press base 18. The first 84 and second 86 frame supports arepivotally connected to the first 72 and second 74 tipper supports,respectively, at the upper mold pivot axis 20. As is shown in FIGS. 1and 2, at each pivot point along the upper mold pivot axis 20, the framesupports 84, 86 include respective first 88 and second 90 upper moldpivots, that is, pivot trunnion mount assemblies. The upper mold pivots,or, pivot trunnion mount assemblies 88, 90 pivotally support the moldpress frame 14 and the upper mold carrier 12 for pivotal tipping motionabout the upper mold pivot axis 20.

As shown in FIGS. 1 and 2, the first 84 and second 86 frame supportsinclude respective first 92 and second 94 tipper plates, each of whichhas an upper semi-circular rim. The tipper plates 92, 94 are "chainplates"--each having a length of roller chain 96 fixed along its uppersemi-circular rim.

The upper mold tipper 19 also includes first 98 and second 100 tippermotors operatively connected between the mold press frame 14 and therespective first 92 and second 94 tipper plates of the frame supports84, 86. As shown by hidden lines in FIG. 1, each tipper motor 98, 100 isconnected through a set of bearings to a single-reduction drive unit102. The single-reduction drive units 102 are each mounted to a tippermotor bracket 104 which is bolted to the rear wall of one of the lifttubes 22, 24 as is representatively shown in FIG. 2. As shown in FIG. 1,each tipper motor 98, 100 drives a respective tipper chain sprocket 106,108 through its respective single-reduction drive unit 102. Each tipperchain sprocket 106, 108 is fixed to a keyed outer end of a drive shaftthat extends from each tipper motor single-reduction drive unit. Eachtipper sprocket 106, 108 is in driving engagement with the length ofroller chain 96 fixed along the outer circumferential rim of one of thetipper plates 92, 94.

Each tipper motor 98, 100 is a Parker #11A-129-AS-0 low-speedhigh-torque hydraulic motor. The single-reduction drive is a Power Wheel#6TB-13-04-K2 drive with a 4.50:1 gear ratio. Each rotator sprocket 106,108 is a Dodge #100B16 Type B 16-tooth sprocket bored to a 2.00"diameter. Each length of chain 96 is a length of #100 single strandroller chain.

The upper mold rotator 21 comprises the first 30 and second 34 slideplate assemblies which, as stated above, are slideably mounted forreciprocal movement along the respective first 22 and second 24 parallellift tubes. As shown in FIGS. 1, 2, 6 and 7, first 110 and second 112stabilizer plates, made from carbon steel plate, are rotatably mountedto the first 30 and second 34 slide plate assemblies, respectively. Thestabilizer plates 110, 112 are rotatably supported in planesperpendicular to the rotation axis 23 on pivot mounts 114, 116 extendingfrom the lift plates 54, 56 of the respective first 30 and second 34slide plate assemblies. The stabilizer plates 110, 112 are bolted tofirst 111 and second 113 opposite ends of the upper mold carrier 12 torotate with the upper mold carrier 12, and any attached upper moldportion, about the rotation axis 23.

As shown in FIG. 1, the upper mold rotator 21 also includes first 118and second 120 idler guides rotatably supported on the lift plates 54,56 of the respective first 30 and second 34 slide plate assemblies. Eachidler guide 118, 120 includes an Osborne #VLRE-31/2-4 V-groovedeccentric idler roller bolted to a carbon steel bracket. The steelbrackets are bolted to the lift plates 54, 56.

As shown in FIG. 1, the idler guides 118, 120 are spaced from therotation axis 23 with their V-grooved rollers supported in a position torotate about respective idler axes 122, 124. The idler axes 122, 124 aredisposed parallel to and above the rotation axis 23. The stabilizerplates 110, 112 have tapered outer circumferential rims that matinglycorrespond to the roller V-grooves of the idler guides 118, 120. Thestabilizer plates 110, 112 are mounted so that their taperedcircumferential rims are in constant guided turning engagement with therespective V-grooves of the idler guides 118, 120 as is best shown inFIG. 1.

As shown in FIGS. 1 and 2, the upper mold rotator 21 includes a rotatorplate 126 that is rotatably and coaxially mounted with and bolted to thefirst stabilizer plate 110. The rotator plate 126 rotates about therotation axis 23 and has an outer semi-circular circumferential rim 128,best shown in FIG. 2, that lies at a constant radial distance from therotation axis 23. The rotator plate 126 is made from carbon steel plateslaminated together by welding.

As shown in FIGS. 1 and 5, the upper mold rotator 21 also includes arotator motor 130 that is operatively connected between the first slideplate assembly 30 and the upper mold carrier 12. As is best shown inFIG. 5, the rotator motor 130 is connected through a set of bearings toa single-reduction drive unit 132. The single-reduction drive unit 132is mounted to a rotator motor bracket 134 which is bolted to a forwardedge of the lift plate portion 54 of the first slide plate assembly 30.The rotator motor 130 drives a rotator chain sprocket 136 through thesingle-reduction drive unit 132. The rotator chain sprocket 136 is fixedto a keyed outer end of a drive shaft 138 that extends from the rotatormotor single-reduction drive unit 132. The rotator chain sprocket 136 isin driving engagement with a length of roller chain 140 fixed along theouter circumferential rim of the rotator plate 126.

The rotator motor 130 is a Parker #11A-054-AS-0 low-speed high-torquehydraulic motor. The single-reduction drive 132 is a Power Wheel#6TB-13-04-K2 drive with a 4.50:1 gear ratio. The rotator sprocket 136is a Dodge #80B19 Type B 19-tooth sprocket bored to a 2.00" diameter.The length of chain 140 is a length of #80 single strand roller chain.

The first end 111 of the upper mold carrier 12 is rotatably supported onthe first upper mold rotator slide plate assembly 30 adjacent therotation axis 23. The second end 113 of the upper mold carrier 12 isrotatably supported on the second slide plate assembly 34 adjacent therotation axis 23. Upper mold portions are mounted to a lower surface ofthe upper mold carrier 12 between the stabilizer plates 110, 112.Mounting feet comprising pieces of angle iron (not shown) attach moldlids to the upper mold carrier frame 12. Other embodiments may employother suitable means for attaching a mold lid to a frame. As shown inFIGS. 6 and 7, the upper mold carrier 12 comprises a rectangularframework of square steel tubing. First 142 and second 144 mountingbrackets are connected to the first 111 and second 113 opposite ends ofthe upper mold carrier 12, respectively. Each mounting bracket 142, 144is made of carbon steel plate and extends perpendicularly upward from anupper surface of the upper mold carrier 12 at each end 111, 113 of theupper mold carrier 12. As is best shown in FIGS. 6 and 7, each mountingbracket 142, 144 includes three steel angle-braces or "gussets" 146spaced along each opposite end of the upper mold carrier 12. The first142 and second 144 mounting brackets are bolted to the first 110 andsecond 112 stabilizer plates, respectively.

The lower mold tipper, generally indicated at 148 in FIGS. 1, 7 and 9,comprises two parallel lower mold carrier lift cylinders 150. The lowerlift cylinders 150 are disposed parallel to each other and diagonally inrelation to the lower mold mounting plate 62. As is best shown in FIG.9, a lower end of each lower lift cylinder 150 is pivotally connected toone of two lower brackets 152. The lower brackets 152 are each fixed toone of two respective downwardly-extending cylinder attachment braces154. An opposite upper end of each lift cylinder 150 is pivotallyconnected to one of two adjacent upper brackets 156 attached to theapproximate center of the lower mold mounting plate 62. Each of thelower mold lift cylinders 150 is a Parker Series 2H hydraulic cylinderwith a 2 inch bore and a 51/2 inch stroke.

An electronic multi-axis motion controller is operatively connected tothe upper mold tipper 19, the lower mold tipper 146, the upper moldrotator 21 and the upper mold lift cylinders 26, 28. The motioncontroller ergonomically positions the upper mold to meet differentoperators' needs and to enable the mold press assembly 10 to accommodatea variety of mold/retainer configurations.

In place of structures described above, other embodiments of the presentinvention may include any one of a number of different structures forattaching the upper mold lift cylinders 26, 28 to the slide plateassemblies 30, 34. Other embodiments may also include other types oflift mechanisms, cylinders with different bores and strokes, or entirelydifferent structures capable of supporting the upper mold carrier 12 forreciprocal, rotational and tipping motions. Other embodiments may alsoinclude alternative structures for guiding and supporting the linearreciprocal motion of the slide plate assemblies 30, 34 as well as othersuitable motor, gear, sprocket and chain combinations. Other embodimentsmay also use other suitable tipper mechanisms and may include idlerguides 118, 120 attached at other points on the slide plate assemblies30, 34. In addition, entirely different structures may be used tostabilize the upper mold carrier 12 in place of the stabilizer platearrangement of the present embodiment. Further, the rotator plate 126,stabilizer plates 110, 112 and other components may be made from othersuitable materials besides carbon steel plate. They may also use othersuitable rotating mechanisms for rotating the upper mold carrier 12 andmay include upper mold carriers of suitable constructions other than thesquare steel tubing framework described above.

In practice, to prepare the mold press assembly 10 to make a part or anumber of identical parts, upper and lower mold portions are attached tothe upper 12 and lower 16 mold carriers, respectively. The motioncontroller is then programmed to operate the upper mold tipper 19, thelower mold tipper 146 and the upper mold rotator 21 and the upper moldlift cylinders 26, 28 through an automatic two-part mold press cycle.

In the first part of the two-part cycle, the upper mold carrier 12 movesthe upper mold portion away from an operator-access position and thelower mold carrier 16 moves the lower mold portion into anoperator-access position. In the second part of the cycle, foam ispoured into the lower mold portion, the upper 12 and lower 16 moldcarriers and mold portions are moved into a press position, and theupper mold carrier 12 and mold portion are returned to theoperator-access position. All motions and dwell positions that the moldcarriers 12, 16 move through during the two-part cycle may be adjustedby re-programming the motion controller.

To make a part, an operator loads the upper mold by inserting a retainerportion of the part to be manufactured, into the upper mold cavity.Retainer loading takes place with the upper mold carrier 12 and moldportion positioned at the end point of the second part of the two-partautomatic cycle, i.e., the upper mold portion is tipped forward, liftedupward along the mold frame 14 toward the operator's approximatechest-level, and rotated into a position to facilitate cleaning andloading. This position is shown, in phantom, as position A in FIG. 2.

After loading the upper mold portion, the operator actuates themulti-axis motion controller to initiate the first part of the two-partautomatic mold cycle. The controller begins the first part of the cycleby tipping the upper mold carrier 12 and mold portion back away from theoperator to a position shown, in phantom, as position B in FIG. 2. Thecontroller then actuates the lower mold carrier lift cylinders 150 andtips the lower mold carrier 16 and mold portion forward approximatelythirty degrees toward the operator, as shown, in phantom, in FIG. 9.This completes the first part of the automatic mold cycle. The motion ofthe upper mold carrier 12 is not limited to a purely vertical lift. Thelift angle may be preset to move the upper mold carrier 12 along anon-vertical path to accommodate part demolding.

Once the first part of the cycle is complete, the operator removes anypart or parts from the lower mold portion that may have been formed in aprevious mold cycle. The operator then loads a shell portion of the partto be manufactured, into the lower mold portion cavity.

After loading the lower mold portion, the operator actuates the motioncontroller, which responds by initiating the second part of theautomatic mold cycle. In the second part of the cycle the controllerfirst rotates the lower mold carrier 16 and mold portion back to thepress position, drops the upper mold carrier 12 and mold portion downand rotates the upper mold carrier 12 and mold portion into an optimumangular position in preparation for mold closing while tipping the uppermold carrier 12 and mold portion either forward toward position A or afttoward position B--whichever position is farther away from the positionfrom which a foam head will introduce foam into the lower mold portion.The foam head then pours the foam into the shell in the lower moldportion:

Once the pour is complete, the upper mold carrier 12 and mold portiontips to a position over the lower mold portion and the controller causesthe upper mold lift cylinders 26, 28 to pull the upper mold carrier 12and mold portion down into the press position over the lower moldportion thus closing the mold. The "press" position is shown as positionC in FIG. 2. The upper mold cylinders 26, 28 maintain downward pressureon the closed mold for a predetermined time. Once the predetermined timehas elapsed, the controller automatically opens the mold by lifting theupper mold carrier 12 and mold portion. The controller then tips theupper mold carrier 12 and mold portion forward toward position A androtates the upper mold carrier 12 and mold portion back into a positionwhere the operator can more easily clean the upper mold portion, i.e.,the operator-access position. The operator then removes from the uppermold portion all debris and residue left behind in the molding processand prepares to re-initiate the first part of the cycle.

I intend the above description to illustrate embodiments of the presentinvention by using descriptive rather than limiting words. Obviously,there are many ways that one might modify these embodiments whileremaining within the scope of the claims. In other words, there are manyother ways that one may practice the present invention without exceedingthe scope of the claims.

I claim:
 1. A method for ergonomically positioning first and second moldsections in an ergonomically adjusted relationship comprising the stepsof:providing a first mold tipper for the first mold section; providing asecond mold tipper for the second mold section; providing a mold rotatorand a mold lift for the first mold section; moving the first moldsection into a chest-level position by actuating said first mold lift;tipping the first mold section toward an operator and rotating the firstmold section to a loading and cleaning position to provide access to theinterior thereof for cleaning and loading; following loading andcleaning of the first mold section, tipping the first mold section awayfrom the operator and rotating it into a position more vertical than insaid cleaning and loading position; thereafter tipping the second moldsection to provide operator access thereto; loading a preform in thesecond mold section and returning the second mold section to a moldpress position; positioning said first mold section verticallydownwardly toward said second mold section and rotating said first moldsection into an optimized angular position in either said cleaning andloading position or said more vertical position to provide foam headaccess to said second mold section; thereafter tipping said first moldsection into a vertically overlying relationship with said second moldsection and operating said mold lift for said first mold section toclose said first mold section against said second mold section and formaintaining pressure therebetween; following a predetermined time,opening said first and second mold sections and tipping and rotating thefirst mold section into the cleaning and loading position for cleaningand thereafter tipping said second mold section for removing a moldedproduct therefrom.